1980 XS11 Special - Mayberry Duck Rebuild

[Radioguylogs]

Think ahead

Hi Kurt,
I would stay with black for the brackets as they are more of a frame part than a trim part. IMHO. The piece that goes on to the top shock mount has broken on both of mine. I would suggest some form of reinforcement in that area.
Phil

I put new aftermarket shocks on the Bagger and now I don't have any thread engagement on the stud that holds the top of the shock and the two bag brackets and the grab bar. You may want to keep an eye on the material thicknesses and the stack-up if you beef up that bracket.

I'll have to
(a) machine the shock grommets thinner
(b) Remove the washers that belong on either side of the shock grommet
(3) file or mill the grab bar thinner

....or some combination of the above

[kboehringer]

Replace with Longer Studs?

I don't have any thread engagement on the stud that holds the top of the shock and the two bag brackets and the grab bar.

Mike,
I see that problem on the horizon as well. When I saw MaximPhil's post I thought.... Gee, I have two full extra sets of the WRONG brackets and could easily double-up that area by sacrificing one of them...BUT, I don't have barely any threads left now! I have rear rack & adjustable backrest installed now but my rear rack does not use the shock tower bolt. I have yet to install the TWO pieces necessary for the bags onto the shock tower.

I have NOT yet looked at it thoroughly but I'm considering replacing the through bolts with another pair of similar style but longer length...HMMMMMMM.....

I would think that Yamaha would have provided longer shock bolts for the Venturers?

KURT

[Radioguylogs]

Hmmmmm

Kurt:

Now you got me thinking.

I wonder if the stud could be removed, or is it welded?

It would be really happy day for me if could replace the stud with a longer one.

Even if we couldn't find a longer one, it wouldn't be hard to make one......

PS: The rotation of my previous shock against the plate left a big crescent shaped divot in the plate. That reinforcement seems like a good idea for this reason and others. My fix to avoid a deeper divot is to have a washer between the shock and the plate.

[kboehringer]

Replacing the Shoulder Bolts...

Kurt:
I wonder if the stud could be removed, or is it welded?
......
Even if we couldn't find a longer one, it wouldn't be hard to make one......

Mike,
The bolt is thoroughly welded in place. But that's nothing a drill & die-grinder can't fix. I mentioned this at some time in the past but got some discouragement at the idea. Honestly, it's not that critical a location so being off a 1mm isn't going to change the performance of the rear suspension.

As you stated, making a comparable replacement shoulder bolt with extended shaft & threads is child's play for anyone with a lathe. Welding it back in place isn't much of a chore either...

As soon as I get DEAD DUCK back together I'll be all over this modification to Mayberry as I want the bags on SOON!

KURT

[Eveready1100]

Guys, just a suggestion........ Instead of surgery to replace the stud, how about sourcing a couple of mag wheel nuts (lugs?) with suitable thread and barrel thickness which would extend the stud to fit virtually anything you'd want to bolt onto them.

[kboehringer]

SWMBO Wanted Blue

I would stay with black for the brackets as they are more of a frame part than a trim part. IMHO. ....Phil

Phil,
I had mentioned to SWMBO that I wasn't sure about color on these. I asked "The Guys" and they suggested keeping them black. She said " I thought a little more COLOR might have looked nice"..... Guess what? They got painted body color!




With the bag installed you can barely see the body color of the brackets.


Now I have to figure out which OEM pieces will be retained and which pieces will be tossed.

These CORRECT brackets have a wider "Shelf" to push the bags further off and allow the pull bar & seat removal that the narrower models don't have. They also have a bottom to support the bags. There is still a need for additional support but I will likely toss the outer ring(s).

KURT

[Gmac]

That makes sense

It also looks nice!

[MaximPhil]

Happy wife Happy life Hi to Nancy. Looks fine to me. you had the paint anyway : Do make sure the bolts holding the bracket are tight to prevent any motion. I suspect mine were / are overloaded at times
Phil

[kboehringer]

Bags Done? - William Approves

XS Folks,
I think I have the bags done except for a cross support (to be fabricated) for the rear. My Grandson William approves? Definitely a Yamaha Man!

William seems ready to take a ride with POP!


The forward brackets had to be completely cut apart. The flanges on the top and bottom were modified and re-oriented to be accepted on the Special Frame. I also heated and reduced the opening of the curve on the brackets from 13-1/4" down to 12-1/2"..

Last weekend I got a peek at Mike P's beautiful XS11 Venture and was able to fabricate some extensions to my standard brackets.


The whole set-up is a combination of self-fabricated pieces and pieces from a standard 11. There isn't another set like this I've been working with Nancy and making sure she would have a comfortable leg & foot area... She's happy with the new set-up.

I'm going to skip the outer ring(s) and give this a shot exclusively with the back brackets and a cross support in the rear. I believe this is a cleaner look and the bags SHOULD have enough support to prevent damage(s). If there is a problem, I'll switch to the older style fiberglass bags which are certainly much stronger than the newer plastic units.

Almost ready for EXTENDED traveling!

KURT

[madmax-im]

Love that shot with little William in the pannier...The bike looks spectacular...Your work is top shelf...

[HalfCentury]

The entire build is worthy of a magazine cover. The logo on the hard bag is a very nice touch.

[kboehringer]

Mayberry basically complete.....Shifting gears to DEAD DUCK

The entire build is worthy of a magazine cover. The logo on the hard bag is a very nice touch.

HalfCentury,
Thanks for the compliment but this bike is far from that level of quality. There are others on this board that do some incredible restorations.

This bike has come a long way from day I picked it up in Mount Airy (aka Mayberry), North Carolina. With that said, this thread is just about done. There may be another post or two but the heavy lifting is all done. The remainder of my work on Mayberry is generally limited to a few routine repair and maintenance items. I'm also planning to promptly replace the rings as my experience with DEAD DUCK has shown that's a pretty easy move and should provide years of trouble free compression.....

Today, I fabricated and installed a custom cross support using bits & pieces of the OEM outer support rails. I re-used the mounting tabs to install an additional set of turn signals (yet to be wired). Because this bagger set-up does not allow use of the OEM signals, I'm concerned the mini signals from China are not quite far enough part nor do they attract enough attention. The second set should resolve that issue once wired.



I decided on the Yamaha Logos to add a little "style" to the bags. Unfortunately, although I have some decent painting skills, my ability to pin-stripe or accent the base paint is much less than admirable. Honestly, I'm pretty horrible with stripes and accent painting. The R1 logos were an easy way to go.



KURT

[MPittma100]

Restoration

HalfCentury,
Thanks for the compliment but this bike is far from that level of quality. There are others on this board that do some incredible restorations.

This bike has come a long way from day I picked it up in Mount Airy (aka Mayberry), North Carolina. With that said, this thread is just about done. There may be another post or two but the heavy lifting is all done. The remainder of my work on Mayberry is generally limited to a few routine repair and maintenance items. I'm also planning to promptly replace the rings as my experience with DEAD DUCK has shown that's a pretty easy move and should provide years of trouble free compression.....

Today, I fabricated and installed a custom cross support using bits & pieces of the OEM outer support rails. I re-used the mounting tabs to install an additional set of turn signals (yet to be wired). Because this bagger set-up does not allow use of the OEM signals, I'm concerned the mini signals from China are not quite far enough part nor do they attract enough attention. The second set should resolve that issue once wired.



I decided on the Yamaha Logos to add a little "style" to the bags. Unfortunately, although I have some decent painting skills, my ability to pin-stripe or accent the base paint is much less than admirable. Honestly, I'm pretty horrible with stripes and accent painting. The R1 logos were an easy way to go.



KURT

Hi Kurt,

This project has turned out well. A lot of work but I'm guessing that it was an enjoyable effort.

The original Yamaha bag option came with a turn signal bar. It mounted to the license tag bracket. Also, the wires for that light bar are already in the tail light harness behind the tag. It looks like that light bar would work with your bags. JAT

http://www.ebay.com/itm/1978-Yamaha-...RVnoRt&vxp=mtr

[motoman]

XS Folks,
I think I have the bags done except for a cross support (to be fabricated) for the rear. My Grandson William approves? Definitely a Yamaha Man!

William seems ready to take a ride with POP!


The forward brackets had to be completely cut apart. The flanges on the top and bottom were modified and re-oriented to be accepted on the Special Frame. I also heated and reduced the opening of the curve on the brackets from 13-1/4" down to 12-1/2"..

Last weekend I got a peek at Mike P's beautiful XS11 Venture and was able to fabricate some extensions to my standard brackets.


The whole set-up is a combination of self-fabricated pieces and pieces from a standard 11. There isn't another set like this I've been working with Nancy and making sure she would have a comfortable leg & foot area... She's happy with the new set-up.

I'm going to skip the outer ring(s) and give this a shot exclusively with the back brackets and a cross support in the rear. I believe this is a cleaner look and the bags SHOULD have enough support to prevent damage(s). If there is a problem, I'll switch to the older style fiberglass bags which are certainly much stronger than the newer plastic units.

Almost ready for EXTENDED traveling!

KURT

Can use a cut piece of stainless pipe on that front upper hole of peg mount along with a bit longer stainless grade8 metric bolt. Cut it just a hair shorter than existing distance of gap in mount plate. That way, peg will pull up tight against mount plate and never rotate out of position. Worked superbly on my Venturer and brought the peg forward for bit more comfort for wife, plus kept her from sliding forward. I just use the road pegs mounted on front crash bars on longer highway rides which keeps her feet from interfering with mine. JAT to consider!

[kboehringer]

2-Up Foot Positions?

Can use a cut piece of stainless pipe on that front upper hole of peg mount along with a bit longer stainless grade8 metric bolt. Cut it just a hair shorter than existing distance of gap in mount plate. That way, peg will pull up tight against mount plate and never rotate out of position. Worked superbly on my Venturer and brought the peg forward for bit more comfort for wife, plus kept her from sliding forward. I just use the road pegs mounted on front crash bars on longer highway rides which keeps her feet from interfering with mine. JAT to consider!

Motoman,
This sounds like the MOD Schming suggested on page #11 of this thread? Is this the same thing?

Honestly, I had some highway pegs mounted on my other XS11's engine guards. I used them once and then quickly removed them. I found it EXTREMELY uncomfortable with my feet up there. Maybe it's my less than 6' size or relatively recent back surgery (L4/L5 & L5/S1 Disc Repair). Regardless, I can't put my feet up there and be AT ALL comfortable. So, I must keep my feet on my pegs.

FYI....All of my XS11's, including this one, have XJ11 pegs installed both front and rear. I find they are a tiny bit wider and provide a better traction/feel than the XS11 peg. IMPO, they also look better.

I've been thinking about giving her a seat belt tying her to the back rest to keep her from sliding forward and pushing "me" into the tank! Only kidding, I know that would be dangerous in a crash, but I had thought about it more than once!

KURT